Today, Industry 4.0 solutions improve production efficiency, reduce costs, and improve overall production quality. This is a breath of fresh air for manufacturers across all industries. The more optimized your production, the better off you’ll be in terms of reputation, customer retention, and more.
However, Industry 4.0 does present a new obstacle for manufacturers to overcome: an efficient Wi-Fi infrastructure. Unfortunately, many manufacturers still face issues today, making it difficult to harness the power of innovative technologies like our tools that provide an onboard controller and Tools Control, a server-based controller platform. That’s why innovation is still ongoing, and new solutions and ways of doing things are discovered, enabling businesses and manufacturing facilities to keep up despite their limitations.
In the automotive industry, every second counts, so it can be frustrating when your tools don't operate properly. Our customer had a similar situation: They were only able to use up to three tools connected to a controller. This article will explore their production challenges and learn how our experts can provide solutions.
A Limited Toolkit: Struggling with Bandwidth Constraints
A major OEM automotive manufacturer wanted to use a Power Focus 6000 (PF6000) with six STB tools with a Bluetooth connection, which is typically supported. However, they also wanted to use eHMIs on the tools. The challenge is that the eHMIs themselves use the same type of Bluetooth connection to communicate with the controller that the tools do, and this limits the number of possible tool connections due to bandwidth constraints. The controller was understood to support up to six tools on six virtual stations.
However, they were using a Bluetooth connection and required eHMIs on the tools; thus, it was later discovered that this was limiting the number of tools they could use at once. Unfortunately, they could only use three due to the eHMIs on the tools taking up too much bandwidth.
From 3 to 20: Unlocking Full Potential with Expert Guidance
Recognizing the need for an improved solution, our experts wasted no time. As soon as IxB Connect was ready, they promptly visited the customer’s facility to present the enhanced solution in person. This is because our PF8 and IxB tools offer two solutions that would solve the customer challenge. Firstly, the way that the screens (eHMIs) communicate with the controller has been improved, so there is no longer a constraint in bandwidth if you want to connect six tools to a controller with screens installed. Secondly, an Access Point allows up to 20 connections, granting them more flexibility and freedom.
The plant was prepared to explore Wi-Fi infrastructure and the possibility of an Integrated controller, but for now, they were limited to a Bluetooth connection. This is where the PF8 and the new Access Point feature come into play. With this feature, we can now connect up to 20 tools to a controller without needing direct access to the plant’s WI-FI, avoiding the limitations they faced with STB tools and the PF6000.
The original demo involved just one tool connected to a Power Focus 8 (PF8) to demonstrate and explain the new features and capabilities. This successful demo led to our customer purchasing 20 Tensor IxB tools to replace their STB tools and a couple of PF8s to replace their PF6000s.
Related: Tune in to our on-demand Pass the Torque webinar, where our experts discuss the advantages of Tensor IxB compared to our STB battery tool.
Atlas Copco solutions: Delivering unbeatable results
The Power Focus 8 and Tensor IxB tooling enhanced connections and expanded the number of virtual stations compared to the current tooling lineup. Additionally, our Tensor IxB tools demonstrated success in our customer’s facility. They featured improved batteries, faster motors, and accessible settings without needing a docking station.
Looking toward the future: Atlas Copco’s lasting impact
Our customer has experienced great success with their new tooling ensemble, which has resulted in the purchase of over 50 additional Tensor IxB tools. These new tools will replace older ones at their facility, enhancing traceability throughout their operations. We believe these tools will support our customer as they begin their journey to upgrade their Wi-Fi infrastructure.
Ready to embrace Industry 4.0 technologies without hindering your production? Contact our experts to discover what solutions are best for your facility.
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